Contact pin wire termination adaptor assembly for electric switches

ABSTRACT

A toggle switch and assembly for effecting connection of wire leads with contact pin terminations to exterior switch terminals is disclosed. A portion of the switch housing adjacent the terminals is mounted and sealed in one end of an insulating base with the terminals engaging separate connector receptacles within individual bores with the base. The wire contact pins are held in locked electrical engagement with respective switch terminals and connector receptacles within the base, and the wires connected thereto are sealed against moisture by a grommet member sealed within the opposite end of the base. The connector receptacles are of a design accepting several different sizes and styles of standard contact pin wire terminations.

United States Patent 7 1111 3,612,801

721 Inventors JamesL.Elli0tt 3,585,945 5/1968 Tums 200/168G Santa Ana, cant; 2,814,704 11 1957 Bald ZOO/I68 0 11 1-61 1 yv. 1111115, New Berlin, Wis. 2,747,036 5/1956 Brodsky et al. 200 168 G x 211 Appl. No. 49,121 1,869,646 8/1932 Anderson 200/168 G [22] Filed June 23,1970

[45] Patented Oct. 12,1971

[7 3] Assignee Cutler-Hammer, Inc.

Milwaukee, Wis.

Primary ExaminerI-l. 0. Jones Attorneys-Hugh R. Rather and William A. Autio ABS'IIRACT: A toggle switch and assembly for effecting connection of wire leads with contact pin terminations to exterior switch terminals is disclosed. A portion of the switch housing 4 Claims 7 Drawing Figs. adjacent the terminals is mounted and sealed in one end of an insulating base with the terminals engagmg separate connec- Cl 4 200/168 G tor receptacles within individual bores with the base. The wire Int-Cl H01h9/04 contact pins are held in locked electrical engagement with [50] Field OI Search G respective switch terminals and connector receptacles within the base, and the wires connected thereto are sealed against [54] CONTACT PIN WIRE TERMINATION ADAPTOR ASSEMBLY FOR ELECTRIC SWITCHES [56] Referenees Cited moisture by a grommet member sealed within the opposite UNITED STATES PATENTS end of the base. The connector receptacles are of a design ac- 3,290,475 12/1966 Bross 200/ 168 G cepting several different sizes and styles of standard contact 3,541,288 11/1970 Maas ZOO/168G pinwireterminations.

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EPOXY CEMENT zz l l Ill PATENTEDUCT 1 2 ml EPOXY I CEMENT Z2 CONTACT PIN WIRE TERMINATION ADAPTOR ASSEMBLY FOR ELECTRIC SWITCHES BACKGROUND OF THE INVENTION The use of contact pin termination devices on flexible stranded wire conductors which are affixed by pressure crimping to a conductor has become increasingly prevalent as a way of making electrical connection within connector or junction blocks and the like. With configurations of the contact pins and connector receptacles like that shown in the Johnson US. Pat. No. 3,110,093, the contact pins are automatically mechanically locked in electrical engagement with a connector receptacle by axial interfit of the pin to a given point within the receptacle. Such contact pin can be removed by use of a special tool which when inserted into the receptacle circumferentially abuts the pin to move locking tabs away from the path of the pin so the latter can be withdrawn.

The primary object of the present invention is to provide an assembly afiording locking electrical engagement between a plurality of separate contact pin wire terminations and exteriorally extending terminal lugs of an electric switch.

Another object is to provide an assembly of the foregoing type which permits use of a number of different sizes of contact pin wire terminations.

A further object is to provide an assembly of the foregoing type wherein the region of electrical connection of the contact pin and switch terminal lugs is sealed against entrance of moisture or liquid while permitting insertion or withdrawal of contact pins and wire attached thereto by use of available types of insertion and extraction tools.

Other objects and advantages of the invention will hereinafter appear.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is an exploded view in front elevation of certain subassemblies that incorporate the invention;

FIG. 2 is a fragmentary view in front elevation to larger scale of a completed switch and connector assembly constructed in accordance with the invention;

FIG. 3 is a fragmentary view in end elevation of the switch and connector assembly shown in FIG. 2;

FIG. 4 is a view in front elevation showing the detail of the mating of a switch terminal and wire terminal in a common receptacle used in the assembly of FIGS. 1 and 2;

FIG. 5 is a view in side elevation of the subassembly shown in FIG. 4;

FIG. 6 is a view in cross section of a switch terminal taken along the line 6-6 of FIG. 1; and

FIG. 7 is a similar cross-sectional view taken along the line 7-7 of FIG. 2.

DESCRIPTION OF THE PREFERRED EMBODIMENT As shown in the drawings, the present invention involves the use of a switch 10 of the toggle lever, operator type, a molded insulating base or body 12, a wire sealing grommet 14, and a molded end cover 16 for the subbase.

Switch 10, which is preferably of the type disclosed and claimed in the copending Hults application, Ser. No. 014,446, filed Feb. 26, I970, is provided with downwardly extending terminal lug 18 which may be assumed to connect interiorally of the casing 10a with stationary and movable contacts. As best shown in FIGS. 2, 5, 6 and 7, each lug 18 on its left side has a convexed surface and on its right side with a concaved surface. Each lug 18 is provided with a main shank portion 180 and a shorter portion 18b of reduced thickness adjacent its free end.

The body 12 at its upper end is provided with a rectangular top operating recess 12a whose lateral dimensions are slightly larger than the corresponding outside dimensions of the switch casing 10a. It also has a bottom opening recess 12b in which is seated the sealing grommet 14. Three circular cross sections, spaced-apart openings or passages 12c extend between and open through the inner end walls of the recesses 12a and 12b. Adjacent the lower ends the passages are of reduced diameter in the region of annual shoulder portions 12d of base 12. Each such shoulder has a notch I2e extending therethrough for a purpose that will hereinafter be explained.

A connector receptacle 20 of the form best shown in FIGS. 3 to 5, is disposed within each of the passages 12c. Eachreceptacle 20 is preferably fonned of a berryllium-copper alloy metal by suitable stamping from a flat strip and then formed by rolling about a mandrel or the like. The portion 20a of such receptacles is of a tapering or generally frustoconical shape, and the portion 20b integral therewith is also tapered but to a much lesser degree than the portion 20a. At the bottom end of the portion 20b is a small tab 200 which seats in the notch 12c in base 12 to thereby hold a receptacle against rotation in a passage 120. The other bottom edge portions seat against the upper face of the shoulder 12d in passages 120. The receptacles 20 are longitudinally split along their portions 20a and 20b and the latter portion has a pair of oppositely positioned ear portions 20d which extend inwardly thereof.

When a casing 100 of a switch 10 is inserted within the recess 12a of body 12, the terminal lugs 18 enter the upper ends of the portions 20a of the receptacles 20 and seat against the left inner side of the portions 20a. Before such insertion of casing 100 into recess 12a, the mating portions of that recess side walls and of casing 10a are treated with an epoxy-type cement which effectively bonds and seals these parts together in a water impervious manner when casing 10a and lugs I8 are seated as just explained.

The sealing grommet I4 is preferably formed of a molded silicone rubber material and has three passages 14a extending therethrough which are aligned with the passages 12c. As can be best seen in FIG. 2 each of the passage 14a has a plurality.

of annular ring portions 14b spaced apart therealong in which are aligned openings of smaller diameter. The cover I6, which is preferably formed of the same material as the body 12 has three openings 16a which register with the bottom ends of the passages 14a in grommet 14. Cover 16 is secured to the lower end of body 12 by a suitable epoxy-type cement.

FIGS. 2 and 3 show a wire termination or contact member 22 secured to an insulated flexible wire conductor 24. Member 22 has a lower, hollow cylindrical portion 22a which is compressively crimped at a plurality of points 22b about its circumference to clamp it in intimate and tight electrical engagement with the inner barred wire of conductor 24. At its upper end portion 220 merges with an annular shoulder portion 22c. Shoulder portion 220 on its upper side joins with a solid cylindrical portion 22d which is beveled at its free end.

When a contact member 22 secured to a conductor 24 as aforedescribed is inserted into an opening 16a and pushed through a passage 14a in grommet l4 and into a receptacle 20 to the portions shown in FIGS. 2 and 3, the portion 22d engages with the portion 18a of terminal lug 18 along its concaved surface.

Resilient inwardly biased tangs 20d struck out from the wall of portion 20b of receptacle 20 snap into place against the portion 22a behind the shoulder 22c to prevent withdrawal of contact member 22. This contact 22 is held in tight electrical engagement with terminal lug 18 to provide electrical connection between conductor 24 and terminal lug 18. The outer diameter of the insulating cover of conductor 24 is greater than the diameter of the openings 141: in the portions 14d so that the latter slightly deformed, lightly grip the insulating cover at a plurality of points therealong in the grommet I4. Thus, a moisture impervious seal is provided when all contacts and conductors are in place in the body 12.

FIGS. 4 and 5 show the use of a somewhat different form of contact member 26 in place of contact member 22. The portions 26a, 26b, 26c and 26d correspond to portions 220 to 224 of contact member 22, but the portion 26d is shorter and of larger diameter than the portion 22d of member 22. When the contact member 26 is inserted into the receptacle 20, the portion 26d engages with the portion 18b of terminal lug I8 rather than the portion 18a as in the base of contact member 22.

Thus, it will be seen that terminal lug 18 together with receptacle 20 permit the use of several different forms of wire terminals or contact members, contact members 22 and 26 being examples of two extreme types that can be accommodated.

If after attachment of a contact member such as the member 22 or 26 to a terminal lug 18 as aforedescribed, it is desired to release the same and withdraw it and any conductor attached thereto, a special removal tool such as that shown and described in the Johnson US. Pat. No. 3,1 10,093 should be used.

We claim:

1. In an assembly affording releasable connection of wire conductors having contact pin type terminations to the external terminals of an electric switch, the combination comprismg:

a. an electric switch having an enclosing case with an operator extending from one side and a plurality of spaced apart terminal lugs extending outwardly from another side thereof,

b. an insulating body having a recess in one end thereof in which a portion of said switch casing is seated in sealed relation, a recess formed in its opposite end and a plurality of openings corresponding in number and spacing to said switch terminal lugs, extending between said recesses,

c. metallic connector receptacles within each of said body openings, each being engaged on its inner wall by a switch terminal lug and having means providing releasable locking engagement of contact pin terminations in place against a switch terminal lug, and

d. a grommet member formed of a resilient material secured in place in the last mentioned body recess and having a plurality of openings extending therethrough which are aligned with said body openings to afford renitent sealed engagement with wire conductors extending therethrough and connected to contact pin terminations locked in place in said connector receptacles.

2. The combination according to claim 1 wherein said connector receptacles each have a generally frustoconical portion within which a switch terminal lug seats in electrical contact and which is adapted to receive and hold the cylindrical shank of a contact pin termination in electrical engagement with said switch terminal lug, and wherein said connector receptacles each have an integral annular portion with at least one struck out inwardly depending resilient tang that is adapted to engage with a portion of a contact pin termination when in place and lock it against withdrawal.

3. The combination according to claim 1 wherein each of the switch terminal lugs is of arcuate shape in transverse cross section with a portion adjacent the free end of thinner cross section than the remainder so as to accommodate use of and electrical engagement with at least two different diameter sizes of contact pin terminations.

4. The combination according to claim 1 wherein an insulating cover is secured to said body to overlie and hold said grommet member in place in said body, said cover having openings therein aligned with each of said openings in said grommet member. 

1. In an assembly affording releasable connection of wire conductors having contact pin type terminations to the external terminals of an electric switch, the combination comprising: a. an electric switch having an enclosing case with an operator extending from one side and a plurality of spaced apart terminal lugs extending outwardly from another side thereof, b. an insulating body having a recess in one end thereof in which a portion of said switch casing is seated in sealed relation, a recess formed in its opposite end and a plurality of openings corresponding in number and spacing to said switch terminal lugs, extending between said recesses, c. metallic connector receptacles within each of said body openings, each being engaged on its inner wall by a switch terminal lug and having means providing releasable locking engagement of contact pin terminations in place against a switch terminal lug, and d. a grommet member formed of a resilient material secured in place in the last mentioned body recess and having a plurality of openings extending therethrough which are aligned with said body openings to afford renitent sealed engagement with wire conductors extending therethrough and connected to contact pin terminations locked in place in said connector receptacles.
 2. The combination according to claim 1 wherein said connector receptacles each have a generally frustoconical portion within which a switch terminal lug seats in electrical contact and which is adapted to receive and hold the cylindrical shank of a contact pin terMination in electrical engagement with said switch terminal lug, and wherein said connector receptacles each have an integral annular portion with at least one struck out inwardly depending resilient tang that is adapted to engage with a portion of a contact pin termination when in place and lock it against withdrawal.
 3. The combination according to claim 1 wherein each of the switch terminal lugs is of arcuate shape in transverse cross section with a portion adjacent the free end of thinner cross section than the remainder so as to accommodate use of and electrical engagement with at least two different diameter sizes of contact pin terminations.
 4. The combination according to claim 1 wherein an insulating cover is secured to said body to overlie and hold said grommet member in place in said body, said cover having openings therein aligned with each of said openings in said grommet member. 